Thermal transport element for use with a heat dissipating electrical assemblage

ABSTRACT

A heat transporting electrical assemblage retained in a retaining unit transports heat between a heat sink and a thermal transport element in fluid communications with the heat sink. The thermal transport element is snugly arranged in a thermal gap between a coplanar thermal wall formed by a wall of both the heat sink and the electrical assemblage. Thermal transport element makes at least partial contact with a portion of the coplanar thermal wall and with a portion of the retaining unit thereby transporting heat from the hotter thermal wall to the cooler frame of the retaining unit.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is related to U.S. application Ser. No.10/328,051, filed Dec. 23, 2002, by Tina P. Barcley, and titled, “MethodOf Transporting Heat From A Heat Dissipating Electrical Assemblage.”

FIELD OF THE INVENTION

The invention relates generally to the field of broad electronictechnology (BET), and in particular to thermal management for wedge-lockmounting into card cages. More specifically, the invention relates to amethod for improving the cooling path from the heat sink on the circuitboard to the card cage chassis.

BACKGROUND OF THE INVENTION

It is well known in the field of electronic technology that overheatingelectronic assemblages containing heat generating components, such asprocessors, transistors, diodes etc., contributes to reducing the lifeof the component or module as well as the overall reliability while inservice. As electrical assemblages or products containing suchcomponents become denser and contain components that have higherwattages per square area, component overheating becomes a larger problemas well as a limiting factor in the reliability of the electricalassemblage. Thus, eliminating or substantially reducing the heat fromsuch components during service must be accomplished before productreliability can be greatly improved. The performance and reliability ofcommercial electronic products are limited by the inability of theproducts to dissipate heat generated by densely packed electricalcomponents. Moreover, a related problem in the electronic art involvescircuit boards configured in a card cage. It is known that limitedprogress has been made in the art for removing heat from such electricalassemblages.

Prior art attempts to address the aforementioned problems have met withlimited success. Some artisans have taken advantage of the heat sinkpositioned on one side of the circuit card/board and the thermal pathbetween the heat sink to the slot of the card cage. Since this is arelatively small area, it is generally deemed to offer limitedopportunities for making this an effective and cost effective heattransfer location. Moreover, it is well known that heat dissipationthrough the wedge lock securing the circuit board has been improved overthe last 10 years with changes in the construction and materials of thewedge-lock. However, it is also well known that there remains aconsiderable challenge in making this an effective means of improvingthe heat transfer from the electrical assemblage. Hence, most of theheat does not transfer through the wedge-lock, but through the back sideof the board or the heat sink. To improve layout area, the heat sink hasbecome more open with cutouts. This technique is known to reduce thestiffness of the assembly, which reduces the resonant frequency. Toincrease the frequency, ribs (both horizontal and vertical) are oftenadded to the heat sink. With a rib of the heat sink aligned with a wallof the wedge-lock, increased thermal path area is now available at the“edge” of the assembly. The associated problem is the air gap betweenthe circuit card/board and the bottom of the receiving slot.

Other prior art attempts to address the aforementioned problem hasresulted in varying degrees of success. In the area of commercialelectronics, such as computer electronics, the most common solution isto utilize costly component constructions. In the automotive electronicarea, costly circuit board materials are generally used to reducecomponent overheating.

Therefore, there persists a need in the art for an electronic assemblagethat operates at considerably cooler junction and board temperatures.Further, there is a need for a cost effective method of reducing theheat generated by hot components in electronic assemblages under highand ordinary service loads.

SUMMARY OF THE INVENTION

The present invention is directed to overcoming one or more of theproblems set forth above. Briefly summarized, according to one aspect ofthe present invention, a method is disclosed for transporting heat froman electrical assemblage. A retaining unit (card cage) securely retainsthe electrical assemblage and wedge lock. A heat sink is arranged influid communication with both the electrical assemblage and the wedgelock such that a rear wall of the wedge lock and a side wall of the heatsink form a coplanar thermal wall. The coplanar thermal wall is spacedapart from an interior wall of said retaining unit to form a thermal gaptherebetween. A heat transfer element is disposed in the thermal gapsuch that at least a portion of the heat transfer element contacts atleast a portion of the coplanar thermal wall and the interior wall ofthe retaining unit for transporting dissipated heat therebetween.

The present invention has numerous advantages over prior artdevelopments. More particularly, the electronic assemblage of theinvention operates at lower temperatures and is, therefore, morereliable. Further, the electronic assemblage can allocate space inproximity to the heat-generating element for specific electrical tracesessential for the design layout. Furthermore, the electronic assemblageof the invention may contain a larger number of standard and thinnerwidth size components.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other objects, features, and advantages of the presentinvention will become more apparent when taken in conjunction with thefollowing description and drawings wherein identical reference numeralshave been used, where possible, to designate identical features that arecommon to the figures, and wherein:

FIG. 1 is an elevated plane view of the heat transporting electricalassemblage of the invention;

FIG. 2 is an elevated plane view of another alternative embodiment ofthe invention;

FIG. 3 is an elevated plane view of still another alternative embodimentof the invention,

FIG. 4 is a plane view of a substantially flat spring type thermaltransport element of the invention;

FIG. 5a is a top plane view of a half sheared hole spring type thermaltransport element of the invention;

FIG. 5b is a top plane view of the corrugated spring type thermaltransport element of the invention; and

FIG. 6 is an elevated side view of a biased clip spring type thermaltransport element of the invention.

DETAILED DESCRIPTION OF THE INVENTION

Turning now to the drawings, and in particular to FIGS. 1 and 2, theelectrical assemblage (circuit board 10 only shown) of the invention isillustrated retained in a retaining unit, such as a card cage 12. Atypical electrical assemblage of the invention includes a circuit board10 and at least one heat dissipating component, such as, a processor,transistor, diode, etc. (not shown) mounted thereon. Card cage 12 has aframe 14, preferably substantially C-shaped, which forms a receivingslot 16 for housing supporting circuit board 10 and heat dissipatingcomponents mounted thereon (not shown). A wedge lock 18 is mounted inthe frame 14 for securing the circuit board 10 in the substantiallyC-shaped frame 14. Wedge lock 18 has a rear wall 20 positioned proximateto an interior wall 22 of the receiving slot 16.

The wedge lock 18 is generally secured to heat sink 26 (described below)by use of fasteners. The wedge lock 18, alternatively, may be secured tothe slot wall. In either mounting configuration, the wedge lock 18, whenengaged, uses pressure caused by the sliding sections (not shown) of thewedge lock 18 to effectively wedge and lock the electrical assemblage 10into the slot. The pressure is maintained across the width of the slotthereby maintaining a gap between the electrical assemblage/wedge lockto the rear wall of the receiving slot 16.

According to FIGS. 1-3, a heat sink 26 is arranged in fluidcommunications with the circuit board 10 (representing the electricalassemblage) and with a bottom wall 28 of the wedge lock 18. While heatsink 26 can have practically any configuration, in the preferredembodiment, heat sink 26 has first wall 30 substantially normal to asecond side wall 32. Further, side wall 32 of heat sink 26 is alignedwith the rear wall 20 of wedge lock 18 so as to form a substantiallycoplanar thermal wall 34 with the rear wall 20 of the wedge lock 18. Athermal gap 36 is formed between the substantially coplanar thermal wall34 and the interior wall 22 of the receiving slot 16. Important to theinvention, a heat transport element 38 is inserted in the thermal gap36. Importantly, thermal gap 36 provides for tolerance and maintenanceof the receiving slot 16. At least a portion of the heat transportelement 38 is in contact with each of the wedge lock 18 and heat sink 26and the interior wall 22 of the card cage 12 for transporting dissipatedbeat therebetween. According to FIG. 3, alternatively, an interfacelayer 40, such as any one of available synthetic and silicone thermalgreases, may be arranged in the thermal gap 36 contacting the heattransport element 38 and the coplanar thermal wall 34. Interface layer40 enables increased heat transport from the electrical assemblage 10during operations. In any event, the thermal gap 36 still needs to bemaintained for tolerances and assembly purposes. Skilled artisans willappreciate that an adhesive cannot be used in the thermal gap 36 due tomaintenance requirements, particularly the need to remove the card cage12.

Referring to FIGS. 4, 5 a, 5 b, and 6, heat transport element 38 maytake practically any form but is preferably a flexible thermal heatconducting material. Preferred forms of flexible thermal heat conductingmaterials include a substantially flat spring 42 (FIG. 4) having a firstwidth 44 and a second width 46, a half-sheared hole spring 49 (FIG. 5a),a corrugated shaped spring 48 (FIG. 5b) and a biased clip spring 50(FIG. 6). Skilled artisans will appreciate that there are severalvarieties of flat spring 42. Any design that provides a biased force inthe thermal gap 36 against the interior wall 22 of frame 14 and thecoplanar planar thermal wall 34 would be preferable. Currently, amaterial with a large portion of copper or beryllium would provide thespring type quality with the thermal properties that are desirable.According to FIG. 4, in one embodiment, the substantially flat spring 42may have a first width 44 larger than the second width 46.Alternatively, substantially flat spring 42 may have a first width 44smaller than the second width 46 (not shown). According to FIGS. 5a and5 b, the half-sheared hole spring 49, the preferred corrugated spring48, respectively, each has a thickness of about 0.007 inches to about0.010 inches. The half-sheared hole spring 49 has half-sheared holes 51.These may be organized in any pattern or spacing. Maximizing the area ofcontact of the interior wall 22 and the coplanar thermal wall 34 willprovide the best design. Moreover, the flexible thermal heat conductingmaterial may be one selected from the group consisting of berylliumcopper, beryllium, copper, stainless steel, and brass, with berylliumcopper being the most preferred. Further, the flexible thermal heatconducting material may even be a thermoplastic or elastomeric plasticmaterial. While the card cage 12 may be made from any thermallyconductive material, aluminum is the preferred material. Other materialsfrom which card cage 12 may be constructed include zinc, brass, copper,and aluminum beryllium metals.

The preferred construction for thermal transport element 38 includes aberyllium copper formed spring. Since the spring is formed, a ductilemetal was used in this construction. The beryllium copper could bereplaced by beryllium, copper, stainless steel, brass, etc. for asimilar formed construction. If the flexible thermal heat conductingmaterial were molded, it would be possible to use a thermal plastic orelastomeric type material. With the “rib” at the edge of the heat sink,a much-increased area is now available for contact to the thermaltransport element 38. It would be possible to use the spring with astandard flat-plate heat sink, but it would be less effective due to thethermal contact area. In the simple thermal model that was made, a blockwas inserted for the spring with a 50% contact factor. A temperaturereduction of 5° F. was realized during experimentation. If more contactarea or a higher percentage of contact area could be achieved, a largertemperature difference could be realized. More contact area can beachieved by optimizing the shape of the thermal transport element 38 toensure maximum contacts, adding an interface material 40 (describedabove) in the thermal gap 36, adding structure to the frame 14 of thecard cage 12. Another way to make the thermal transport element 38 moreeffective would be to conduct more heat to that edge of the circuitboard 10. A heat sink 26 with more conduction paths to the edge wouldmake the thermal transport element 38 more effective and hence reducethe temperature an even larger amount. This design uses an aluminum cardslot—if brass, copper, aluminum beryllium metal, etc. were used, thenthe thermal transport element 38 would also be more effective.

In another aspect of the invention, a method of transporting heat froman electrical assemblage (circuit board 10 only shown) retained in aretaining unit is herein disclosed. The retaining unit, or card cage 12,has a wedge lock 18 for securing the electrical assemblage 10 in theretaining unit A heat sink 26 is arranged in fluid communications withboth the electrical assemblage 10 and the wedge lock 18 such that a rearwall of the wedge lock 18 and a side wall of the heat sink 26 form acoplanar thermal wall 34. Coplanar thermal wall 34 is spaced apart froman interior wall 22 of the retaining unit or card cage 12, to form athermal gap 36 therebetween. A thermal transport element 38 is disposedin the thermal gap 36 such that at least a portion of the thermaltransport element 38 contacts at least a portion of the coplanar thermalwall 34 and the interior wall 22 of receiving slot 16 for transportingdissipated heat therebetween.

The invention has been described with reference to a preferredembodiment. However, it will be appreciated that variations andmodifications can be effected by a person of ordinary skill in the artwithout departing from the scope of the invention.

PARTS LIST

10 electrical assemblage represented by circuit board

12 card cage

14 frame

16 receiving slot

18 wedge lock

20 rear wall

22 interior Wall

26 heat sink

28 bottom Wall

30 first wall

32 second side wall

34 coplanar thermal wall

36 thermal gap

38 heat transfer element

40 interface layer

42 flat spring

44 first width of spring 42

46 second width of spring 42

48 corrugated spring

49 half-sheared hole spring

50 biased clip spring

51 half-sheared hole

What is claimed is:
 1. A heat transporting electrical assemblage,comprising: a card cage retaining said electrical assemblage, said cardcage having a frame, a receiving slot formed in said frame and a wedgelock which secures said electrical assemblage in place in said receivingslot, said wedge lock having a rear wall positioned proximate to aninterior wall of said receiving slot thereby forming a gap between saidrear wall of said wedge lock and said interior wall of said receivingslot; a heat sink having a first wall and a substantially normal secondwall, said first wall being arranged in fluid communications with saidelectrical assemblage and with a bottom wall of said wedge lock, andsaid substantially normal second wall being substantially coplanar withsaid rear wall of said wedge lock to form a substantially coplanarthermal wall, said substantially coplanar thermal wall and said interiorwall having a gap therebetween; and, a thermal transport elementinserted in said gap, said thermal transport element having at least aportion thereof in contact with each of said wedge lock, said heat sink,and said interior wall of said receiving slot for transportingdissipated heat therebetween.
 2. The heat transporting electricalassemblage recited in claim 1 wherein said heat transport element is aflexible thermal heat conducting material.
 3. The heat transportingelectrical assemblage recited in claim 2 wherein said flexible thermalheat conducting material is a corrugated shaped spring.
 4. The heattransporting electrical assemblage recited in claim 2 wherein saidflexible thermal heat conducting material is a corrugated shaped halfsheared hole spring.
 5. The heat transporting electrical assemblagerecited in claim 2 wherein said flexible thermal heat conductingmaterial is a biased clip spring.
 6. The heat transporting electricalassemblage recited in claim 2 wherein said flexible thermal heatconducting material is a substantially flat spring having a first widthand a second width, said first width being larger than said secondwidth.
 7. The heat transporting electrical assemblage recited in claim 2wherein said flexible thermal heat conducting material is asubstantially flat spring having a first width and a second width, saidfirst width being smaller than said second width.
 8. The heattransporting electrical assemblage recited in claim 3 wherein saidcorrugated shaped spring has a thickness of about 0.007 inches to about0.010 inches.
 9. The heat transporting electrical assemblage recited inclaim 2 wherein the thermal heat conducting material is a materialselected from the group consisting of beryllium copper, beryllium,copper, stainless steel, and brass.
 10. The heat transporting electricalassemblage recited in claim 2 wherein the thermal heat conductingmaterial is a thermoplastic or elastomeric plastic material.
 11. Theheat transporting electrical assemblage recited in claim 1 wherein saidcard cage is made of aluminum.
 12. The heat transporting electricalassemblage recited in claim 1 wherein said card cage is made of amaterial selected from the group consisting of brass, copper, andaluminum beryllium metals.
 13. The heat-transporting electricalassemblage recited in claim 1 wherein said card cage is made ofberyllium copper.
 14. The heat transporting electrical assemblagerecited in claim 1 wherein an interface material is arranged in said gapcontacting said heat transport element and said coplanar thermal wall.